A REWARDING RECYCLING PARTNERSHIP

viscoNEWS issue #10 · May 2018

Unifi, Inc. is a global textile solutions provider and one of the world’s leading innovators in manufacturing synthetic and recycled performance fibers. Through REPREVE®, one of Unifi’s proprietary technologies and the global leader in branded recycled performance fibers, Unifi has transformed more than 10 billion plastic bottles into recycled fiber for new clothing, shoes, home goods and other consumer products.

How it is made

Recycled plastic bottles are picked up curbside and taken to materials recovery facilities across the eastern United States. After the removal of undesirable materials the bottles are then chopped into flake. In the REPREVE Recycling Center in Yadkinville, N.C. the flake is blended and melted into chip. After being melted a second time and extruded in the spinning process into continuous filaments to make REPREVE “first quality” recycled yarn which is made into new products people wear and use every day and make brands like Levi’s and Ford more environmentally responsible. In addition to REPREVE yarn, Unifi supplies customers around the world with superior quality REPREVE flake and chip which is used in various products including nonwovens, carpeting and food grade packaging. That is where viscotec’s Solid State Polycondensation (SSP) unit comes in.

A state-of-the-art solution

Unifi chose Starlinger recycling equipment to start processing its own REPREVE. Since then, Unifi has increased its capability and capacity by adding multiple recycling and SSP lines. In 2017, Unifi added its second viscoSTAR SSP to supply a high iV, decontaminated flake or chip to the market. “We chose viscotec because they have the best and most efficient technology that provides the versatility and precision to meet the demands of a strict and diverse market,” says Corey Tate, Engineering & Technical Manager for Unifi. “viscotec’s commitment to the highest standards and quality machinery ensures we are able to deliver a sustainable, safe and high-quality product,” he adds.

Growing together

With the addition of the fourth Starlinger recycling line and second viscotec SSP line, Unifi is able to continue expanding its capacity while maintaining its commitment to sustainability as the company has set a goal of recycling 20 billion bottles by 2020, and 30 billion by 2022.